First, the basic knowledge of hoisting machinery safety technology

Definition of hoisting machinery:

Hoisting machinery is a kind of handling machinery that lifts, lowers and horizontally moves materials in intermittent operation. The operation of hoisting machinery usually has the nature of repeated cycle, and a complete operation cycle generally includes such links as taking things, lifting, translating, lowering and unloading. Frequent starting, braking and back and forth movement are the basic characteristics of lifting machinery. Widely used in industry, transportation, construction, commerce and agriculture.

Classification of hoisting machinery:

According to the different activities of the hoisting mechanism, it can be divided into:

1. Lifting machinery with single-acting lifting mechanism can only take off and land materials or personnel at fixed points, such as pulleys, hoists, elevators, etc.

2. The electric hoist with running mechanism can load and unload materials along a certain route.

3. The crane can move materials in three coordinate spaces, which can be divided into bridge type and rotary type.

■ Relevant regulations and standards

GB 6067-85 Safety regulations for hoisting machinery

GB 6720-86 Safety Technical Assessment Standard for Crane Drivers

Gb5082-85 hoisting command signal

The basic safety principles of mechanical equipment are applicable to hoisting machinery. These basic principles are: the manufacturing quality of the equipment itself should be good, the materials should be firm, have sufficient strength and have no obvious defects. All equipment must be tested and routinely checked to ensure its integrity. Use the right equipment.

(1) Main hazard types

1) Overturning: it is caused by unstable foundation, running beyond the working capacity of the machine and encountering obstacles during operation;

2) Overload: exceeding the working load, exceeding the running radius, etc.

3) Collision: collision with buildings, cables or other cranes;

4) Foundation damage: the equipment is placed above the pit or sewer, and the support frame fails to extend and support on the solid ground;

5) Operation error: due to limited vision, lack of skill training;

6) Load loss: the load falls off from the hanging rail or sling.

(2) Eliminate danger

In order to prevent the occurrence of hoisting machinery accidents, the following matters should be paid attention to.

1) Identification and inspection: All cranes must pass the inspection, and the manufacturer needs to give the signature certificate of each inspection result. The test results should be consistent with the instructions for use, which must clearly indicate the safe workload. Cranes are not allowed to work beyond the rated load.

2) Maintenance: The crane should be inspected regularly, and any defects should be repaired immediately. Inspection records shall be kept.

3) Safety measures: In order to make the crane run safely, the following series of safety measures need to be considered.

(1) load display, there are two types:

A. load radius indicator;

B. Automatic safety load indicator capable of providing audible and visual warning.

② Control: it should be "fool" type and clearly marked;

③ Limiter: In order to prevent the hook and pulley block from exceeding the travel range, necessary safety limiters should be set;

④ Access: Safe access conditions should be provided for operators, which should also be available in maintenance, testing and emergency situations;

⑤ Operating position: It should have a good line of sight relative to the hook and load, which is easy to control and operate;

⑥ Crew: Without approval, no outsiders are allowed to enter the operation room, and no one is allowed on the derrick;

⑦ Hangers: rings, slings, cables, bolts, shackles, etc. It must be tested, undamaged and installed correctly, with obvious signs and safe workload, and used correctly (don't use it at sharp corners or abnormal angles).

4) Operation area: Dangers near the operation area, including overhead cables and exposed power facilities, should be identified, removed or safely protected. The crane should be firmly supported, and the scale and strength of the newly installed crane should be clear. It is necessary to detect the possibility of collision with other cranes or buildings.

5) Operator training: Operators and loaders of cranes must be healthy and can meet the requirements of work intensity. As a special equipment operator, special training is needed.

Motor vehicles in the factory should be well-made and defect-free, and the load, capacity and type should be suitable for the purpose. The type of power source used by the vehicle should be checked, because the nature of the work area may determine that a specific type of vehicle should be used. In an unventilated closed space, it is not advisable to use a powered vehicle with an internal combustion engine, because it will emit harmful gases. The vehicle should be maintained to avoid the failure of important components (such as brakes, steering wheel and lifting parts). Any damage should be reported and repaired in time. Operators should have safety protection measures on their heads. Motor vehicles and their accessories in the factory shall be used according to the requirements of the manufacturer.

(1) Possible problems

1) Overturning: Overturning may occur when lifting heavy objects too fast, driving too fast, peeling suddenly, colliding with obstacles, using a front shovel when there is a heavy object, going downhill when there is a heavy object in front of the vehicle, crossing a slope or turning or unloading on a slope, driving on an unsuitable road surface or supporting conditions, etc.

2) Overload: exceeding the maximum load capacity of the vehicle.

3) Collision: collision with vehicles such as buildings, pipelines and deposits.

4) Floor defect: the floor is not firm or has insufficient bearing capacity. When using a vehicle, you should find out the bearing capacity of the floor (except the bottom floor).

5) Loss of goods; If the equipment is not suitable, it will cause the goods to slip off the forklift.

6) Explosion and combustion: Short circuit of cable, rupture of oil pipe, dust accumulation or hydrogen generated during battery charging may all lead to explosion and combustion. When transporting combustible gas, the vehicle itself may also become a fire source.

7) Passengers: Passengers shall not be carried without chairs and corresponding facilities.

(2) Eliminate danger

In order to use industrial heavy vehicles safely, the following items should be noted:

1) Workplace: The ground should be suitable for vehicles to drive, the ground should be flat, and there should be no obstacles on the vehicle movement route. The layout of site stacking and storage should be reasonable. When vehicles and workers must walk in a limited space, it is necessary to provide necessary passages and specify clearly marked action routes. No pedestrians are allowed to enter the operation area, otherwise, clear signs or appropriate warning signals should be set on the passage to indicate the order of priority actions.

Appropriate lighting conditions shall be provided for access and stacking operations. The loading area should be laid out reasonably, and a triangular wedge should be provided for vehicle parking to stabilize parking. Within the allowable load range, the slope of the ground shall not exceed 1: 10, otherwise, vehicles designated by the manufacturer that can run on steep roads under a given load shall be used. The battery charging area should be separated from the operation area, and smoking, ventilation and open flame are required.

2) Training: Operators are required to pass the training and pass the examination before issuing certificates.

Second, the lifting operation safety measures

1. Lift without lifting.

1) The command signal is unknown or the command does not hang;

2) Overload does not lift;

3) The workpiece is not fastened firmly and does not hang;

4) someone on the hanging object does not hang it;

5) The safety device fails and does not hang;

6) The workpiece is buried underground and not hoisted;

7) The light is dim and you can't see clearly.

8) The cable-stayed workpiece is not hoisted;

9) there is no measure not to hang angular objects;

10) If the ladle is too full, it will not be hoisted.

2. Matters needing attention in lifting operation

1) It is forbidden to stand under the boom.

2) Level the whole machine before work.

3) Stop the operation when the wind force is greater than 6.

4) When lifting, do not pull the handle of the leg control valve. If it is necessary to adjust the legs, the weight must be placed on the ground, and the boom is located at the front lower side or the rear lower side, and then the adjustment is made.

5) When the heavy objects are parked in the air for a long time, the driver shall not leave the control room.

6) The operation shall be balanced and gentle, and it is forbidden to jerk, shove and operate violently, and it is forbidden to expand and contract with load.

7) Do not use a crane to lift or pull out buried or frozen objects.

8) Under any lifting condition, the number of turns of the wire rope on the lifting drum shall not be less than 3.

3. Basic safety specifications for lifting operation

1) For major lifting projects, the construction scheme and safety measures must be formulated, and the construction can only be started after disclosure;

2) When the lifting capacity reaches the rated load of lifting machinery, two or more lifting machinery will lift the same object, and lift large pieces that are precise and difficult to lift in complex places. When the crane works under or near the high-voltage transmission line, it must apply for a safe construction working ticket;

3) Hoisting machinery should be equipped with fire-fighting equipment, and insulating rubber mats should be laid in the operation room. It is forbidden to pile up flammable items;

4) Bridge cranes such as tower cranes should have reliable lightning protection devices;

5) crane work should have a unified command and signal, and the command should be carried out with flags and whistles. It is not appropriate to use walkie-talkie to direct communication alone. The commander should be an experienced assembler;

6) Before the crane is started and lifted, the driver should signal and irrelevant personnel should leave the operation area. When lifting heavy objects, no one is allowed to stand on the lifted heavy objects or boom;

7) It is forbidden for the crane to perform three actions at the same time. When the weight is close to the rated load, only one action is allowed at a time. When the cantilever crane is fully loaded, it is forbidden to put down the boom;

8) When the crane encounters power failure after work or at work, the controller should be restored to zero first, and then the power supply should be cut off;

9) In case of heavy snow, fog or thunderstorm, lifting operation shall not be carried out in the open air. When the scene lighting is insufficient; The lifting operation should be stopped.

10) In case of gale of magnitude 6 or above, the open-air hoisting operation shall be stopped;

1 1) When lifting large pieces, they must be tied firmly. The hanging point of the hook should be on the same vertical line with the center of gravity of the hook. Hook wire rope should be kept vertical, and it is forbidden to hang it obliquely. When dropping the hook, it is necessary to prevent the sling from deviating due to the local landing of the lifting piece, and it is forbidden to loosen the hook before the lifting weight is fixed;

12) Explosives and dangerous goods (compressed gas cylinders, acids, alkalis, combustible oil products, etc. ) shall not be lifted. When lifting is necessary, reliable safety measures should be taken and the lifting can only be carried out after the approval of the engineer.

4. Key points for safe operation of crane drivers.

1) Lifting equipment must be operated by personnel with special operation certificate;

2) Before each shift, carry out no-load test to check whether there are any defects in each part and whether the safety device is safe and reliable;

3) Fully communicate with the ground commander. Before the crane runs, a signal should be given to prohibit the lifted objects from crossing the overhead;

4) Crane operation must be carried out according to five standards: stability, accuracy, rapidity, safety and rationality;

5) When lifting heavy objects to the lowest position, the wire rope stored on the drum shall not be less than two times;

6) When lifting heavy objects close to the rated load, try to lift them first, that is, take off and land once in the air not too high from the ground, and check whether the braking device is reliable.

Three, lifting operation safety operation procedures

1. Lifting operators must hold a special type of work (lifting) operation certificate.

2. Before hoisting operation, safety warning signs shall be set at the hoisting site in advance, and special personnel shall be assigned for monitoring. Non-lifting workers are not allowed to enter.

3. Lifting operators must wear safety helmets, and aerial work must wear safety belts. Before each lifting operation, the lifting equipment, hoist, wire rope, wind rope, hanging buckle and other machines and tools shall be inspected. If there is abnormality, it should be ruled out before operation.

4. The lifting objects should be tied firmly. The hanging point of the hook should be on the vertical line of the center of gravity of the hoisted object, and the hook wire rope should be kept vertical, and cable-stayed is not allowed. When dropping the hook, it is necessary to prevent the hanging rope from deviating due to the local landing of the hanging object. It is forbidden to loosen the hook when the hanging object is not fixed.

5. When lifting large or irregular parts, a firm sliding rope should be attached to the hanging parts.

6. Before lifting, check the hoisting machinery and its safety devices; Suspend lifting when the lifting piece is about 10cm from the ground, and conduct a comprehensive inspection, and officially lift it after it is confirmed to be normal.

7. Irrelevant personnel in the lifting operation area shall not stay or pass; During lifting, no one is allowed to stay or pass under the boom and the hoisted object. When the lifted objects must be handled, reliable support measures should be taken and the crane operator should be informed.

8. When lifting heavy objects, the crane should generally take the lifting channel, and it is forbidden to cross from above the personnel's heads.

9. It is forbidden to use running equipment, pipes, scaffolding, platforms, etc. As a support point for lifting heavy objects; When the components of the structure or equipment are used as supporting points for lifting heavy objects, it should be explained; When using structures, the consent of the original design unit should also be obtained.

10. Lifting commanders must be trained in safety technology by relevant departments according to the provisions of GB5082, pass the examination and obtain the certificate before taking up their posts.

1 1. The command signal sent by the commander must be clear and accurate.

12. At the beginning of lifting, command with micro-motion signal first, and then command with normal speed after the load leaves the ground 10cm~20cm is stable. When the load is finally in place, it should also be commanded by the micro-motion signal.

13. Commanders should stand in a safe position so that drivers can see the command signals clearly. When executing the load operation command, the load should be commanded to avoid people and obstacles at any time.

14. When the commander can't see the driver and the load at the same time. It is necessary to increase the number of middle-level commanders and transmit signals step by step. When an error signal is found, a stop signal should be given immediately.

15. Before the cargo lands, the commander must confirm that the landing area is safe before sending the landing signal.

16. When more than one person is bound by the same load, before lifting, the call should be answered first, and only one person can be in charge of the command after confirming that the binding is correct.

17. When two cranes lift the same load at the same time, the commander should command each crane with both hands to ensure synchronous lifting.

18. Commanders should wear obvious signs, such as armbands marked with the word "command", helmets with special colors, work clothes, etc.

19. The driver must obey the command of the commander. When the command signal is unknown, the driver should send a "repeat" signal to ask, and the command intention is clear before driving.

20. The driver must be familiar with the standard general gesture signals and related command signals, and work closely with the commander.

2 1. When the signal sent by the commander violates the provisions of this standard, the driver has the right to refuse to implement it.

22. The driver must ring a warning bell before driving, and when necessary, ring a bell to inform people threatened by the load on the ground to evacuate.

23. In the process of lifting, the driver should obey the "emergency stop" signal sent by anyone.

Four, the prevention of lifting injury accidents

1. Lifting all materials with lifting equipment must be commanded by personnel with contractor's certificate, and bulk materials can only be lifted after the hanging basket device or special container is installed.

2. Before hoisting operation, the hoisting area should be set up in advance and supervised by special personnel. Non-hoisting operators are prohibited from passing or staying in the hoisting area.

3. Before each hoisting operation, the on-site commander shall conduct various safety inspections on hoisting equipment, chain block, wire rope, snap ring and other machines and tools, and work can be started only after the abnormality is eliminated.

4. To bind the heavy objects firmly, safety protection measures such as semicircular pipes, wooden boards and rubber must be taken to protect the rope from being cut when it passes through the angular sharp cutting edge. It is strictly prohibited to lift the object with sharp edges, no protective measures or inadequate protective measures.

5. The lifting point of the hook should be on the vertical line of the center of gravity of the hoisted object, and the hook wire rope should be vertical, and it is not allowed to tilt. When dropping the hook, it is necessary to prevent the hanging rope from deviating due to the local landing of the hanging object. It is forbidden to loosen the hook when the hanging object is not fixed.

6. At the beginning of lifting, the lifting commander should use the micro-motion signal to command first. When the heavy object is lifted about 10cm from the ground, the lifting should be suspended and comprehensively inspected, and the lifting can be officially started only after it is confirmed to be normal. When the load is finally in place, it should also be commanded by the micro-motion signal. When lifting large or irregular parts, a strong sliding rope should be tied to the lifting piece.

Five, the use of wire rope safety regulations

1. Wire rope shall not be overloaded or impacted in use. Should be placed on the edges and corners of the suspended object. If more points or more circles are stressed in the binding process, attention should be paid to ensure that the steel wire rope is evenly stressed.

2. The wire rope should be coiled and stored in a dry place after use, and checked, oiled and maintained regularly.

3. Don't rub the wire rope with other objects when the machine is running.

4. Wire rope is forbidden to contact with charged metals (including cables and welding wires) to avoid burning out or reducing its tensile strength after heating. Insulation measures should be taken when working on electric welding lines or live areas, and insulation measures should be taken when using wire ropes on objects close to high temperature.

5. Wire rope connection

5. 1 When connecting with rope clips, the following requirements shall be met:

Φ 7-16mm wire rope requires 3 rope clamps.

φ 19-27mm steel wire rope, and the number of rope clamps required is 4.

Φ φ28-37mm steel wire rope, and the number of rope clamps required is 5.

Φ 38-45 mm wire rope requires 6 rope clamps.

At the same time, the connection strength shall not be less than 85% of the breaking force of the wire rope.

5.2 The rope clamping plate should be at the long end side of the wire rope, and the rope clamping distance should not be less than 6 times the diameter of the wire rope.

6. If the position of multiple strands remains unchanged, the friction loss is slight, and the cordless strands are raised, the joint degree is 100%, which can be used in important occasions.

7. When any of the following phenomena occurs, the compatibility is 75%, which can be used in general occasions.

(1) Each wire rope has displacement, flattening and protrusion, but its core is not exposed;

(2) Some parts of the wire rope have rust marks;

(3) There is no confusion between shares;

(4) there is no phenomenon such as femoral process, scaling and slight twist of the thigh;

(5) When individual steel wires on the rope surface have spikes (broken wires), the number of spikes per meter length shall not exceed 3% of the total number of steel wires;

8. In case of any of the following phenomena, the sharing degree is 50%, which can be used in secondary occasions:

9. The number of spikes on the surface of steel wire rope shall not exceed10% of the total number of steel wires per meter;

10. Some parts are bulging, squashed and displaced, but the total length does not exceed 40% of the total length, and the rope core is not exposed;

1 1. Some parts have obvious rust;

12. There is confusion between individual stocks and stocks;

13. Femoral process is not obvious;

14. Judgment of scrapping

15. The whole stock is broken.

16. When the fiber core of the rope is damaged or the steel wire inside is broken, the diameter of the rope is obviously reduced.

17. External and internal wear and corrosion have been proved to be serious.

18. Strands and steel wires are squeezed, squashed and twisted, the diameter of the rope locally increases or decreases, the core of the rope is exposed in a wave shape, and the outer steel wire is partially stretched into a cage shape.

19. Damage or damage caused by arc action.

Just modify it.